alternator studs attaching to engine block sheared off...

[debstee25]

...and on campsite in Oxfordshire (farmoor). Debating whether to get recovery home (60 miles) or try and get fixed locally. Alternator is held by other bolts, but is twisting slightly making the fan belt screech on occasion. More concerned about sheared bolts coming free when driving. Any advice welcomed... Watercoooled 1988 Dj engine. I guess main concern is whether it's likely that engine will need to come out.

[itchyfeet]

Id say its not a local repair job, id nurse it home then get it sorted, probably get the studs removed in situ by welding nuts on, they may even come out quite easily.
Dont worry about a noisy belt but do keep an eye on the charge light and temp guage if it comes on you must stop as the belt also drives the waterpump
If i remember there are two studs on the lower bracket and one on the tension bracket, whats broken no more than one surely or it would be hanging off?

[tonytech]

Mine has been like that for about 6 months.
I use the van as a daily driver.
The two bolts that hold the lower bracket to the engine sheared (below the surface) and the alternator is only held by the diagonal "tensioning" bracket.
I took the alternator off and decided the engine needed to come out to let me drill the remaining studs.
But I havent got around to it yet.

T

[AdrianC]

Alternator is held by other bolts, but is twisting slightly making the fan belt screech on occasion.

It's more likely to be the belt slipping that's causing the screech. Ours started to screech with the odd brief charge light from cold start. Turned out to be one bolt from the bracket had gone completely awol and the other'd sheared. Fortunately, there was enough thread still there to be able to just wind what was left out of the block - you might be similarly lucky. If so, then it's about a ten minute job, with a couple of shortish M8 bolts the only parts you'll require.

More concerned about sheared bolts coming free when driving.

If it does start to slip, then the worst that'll happen is the belt'll come off. But, of course, the belt also drives the waterpump. So... If you see the charge light come on, STOP IMMEDIATELY and check. But, with that in your mind, I'd drive it. The alternator'll be under heaviest load when you first start, and it's trying to replace the charge the starter motor just used. If it survives that, odds are you'll get home just fine.

[itchyfeet]

decided the engine needed to come out to let me drill the remaining studs.
T

I watched what2d welding nuts with a mig onto rusty stud stumps at the weekend and removing studs from an engine head, its the best solution, you can drill and helicoil but the problem is there is often not enough space to get a drill in

Well worth finding somebody with a mig welder and a supply of m10 nuts before taking the engine out

[debstee25]

found a great garage who managed to heat up bolt and replace one of the bolts. the other one will need to be drilled out as mentioned, so will look more into mig option, cheers